Selective Catalytic Reduction and Exhaust Gas Recirculation

Systems Optimization

© Clean Diesel Technologies, Inc www.cdti.com 1

Abstract
„ The first generation of on-board vehicle urea-selective catalytic reduction systems generally employed
compressed air to achieve efficient injection and the atomization of urea into the exhaust stream and for uniform
ammonia delivery fro reduction of nitrogen oxides across the SCR catalyst. The field experience with these SCR
systems has shaped the requirements for the next generation of systems. These requirements include
substantially reduced system cost and complexity, enhanced durability and accuracy of urea delivery, to control
injection across the full duty cycle and operating temperatures, and to maintain system cleanliness, avoiding
potential for injector and system deposits.

„ This experience has resulted in the demand for a new generation of airless injection systems, such as the airless
ARIS® technology, which incorporates single fluid return flow liquid cooled injection for reliability, simplicity and
low cost. The ARIS airless injection system and control technologies have imbedded a series of performance
refinements. The ARIS approach provides robust and flexible designs for SCR systems in OEM or retrofit
applications.

„ In order to enable manufacturers and Tier One suppliers to optimize NOx and PM control while minimizing fuel
consumption, the strategy for the combination of EGR with SCR was invented. This patented EGR - SCR
approach from Clean Diesel Technologies was shown to readily meet the 2010 requirements for NOx and PM
emissions, through independent test programs. This strategy enables the engine manufacturer to optimize in-
cylinder combustion conditions with EGR, and to integrate with SCR at reduced EGR rate to achieve low NOx
emissions with fuel efficiency over the entire engine operating range. This combination can be optimal using an
efficient SCR injection and control strategy such as ARIS. The operating principles and examples of applications
experience with these systems will be provided.

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by Clean Inc
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Urea / Ammonia injection: Enabling SCR technology

„ Initial SCR systems designed for EURO IV Heavy duty employed air
assisted Urea injection systems to ensure adequate injector cooling and
urea dispersion in the exhaust

„ Next Generation Airless Urea Injection systems have become available,

offering simplified and more cost effective solutions for Urea injection

„ Urea (Diesel Emissions Fluid - DEF or AdBlue aqueous solution) has

become the preferred reagent for SCR applications in Europe and the
U.S.

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by Clean Inc
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SCR technology optimization

Electrical/Electronic
ƒ Power to operate system including pump and injector. Information from
the CAN bus communication providing information on engine load and
rpm. Additional system inputs include: ambient humidity, exhaust
temperature and back-pressure as well as urea tank level.
Hydraulic
ƒ Adequate urea supply pressure is required for proper atomization of urea.
Plus the system must provide adequate flow volume for cooling purposes
due to the harsh environment the injector is subjected to.

Mechanical
ƒ The injector must be controlled by the ECU to inject the precise amount of
urea required for any exhaust flow condition. The injector must be sized
and controlled to be able to deliver the maximum amount of urea required.

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by Clean Inc
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SCR technology optimization

Chemical
ƒ Urea needs to be supplied to match the exhaust rate of flow and the NOx
concentration so the formation of ammonia occurs in correct proportion to maximize
effectiveness and minimize slippage.
Fluid Dynamics
ƒ The mixing of the injected urea in the exhaust stream must be complete and
atomized adequate to thoroughly interact with exhaust chemistry. The exhaust
stream prior to the SCR catalyst inlet must be engineered to provide for adequate
residence time for decomposition of the urea mixing of the exhaust. All of this has
be completed in a extremely short interval of time.
Catalytic Activity
ƒ SCR Catalyst must be sized correctly to allow for adequate residence time for
catalytic activity to occur and not adversely affect engine back-pressure. The
correct catalyst type is required to match the exhaust temperature requirements of
the engine.

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by Clean Inc
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Airless technology vs. compressed air

Most Heavy Duty vehicles have compressed air for braking purposes. Most
Light Duty vehicles especially passenger vehicles do not have compressed air
Airless solutions are advantageous to both markets

ƒ Air compressor adds cost

ƒ Maintenance and reliability of an air compressor is an undesirable feature
ƒ Power required to operate an air compressor reduces fuel efficiency
ƒ Compressed air lines can be troublesome with vibration breakage and moisture
accumulation resulting in potential freeze problems.
ƒ Fouling of intake filters adds to required maintenance
ƒ Weight of a compressor adds load to an engine
ƒ Locating a compressor and lines on a vehicle can be challenging and costly

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by Clean Inc
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Advanced Reagent Injection System (ARIS)

Airless Urea Injection Overview:

• Clean Diesel Technologies’ Advanced

Reagent Injection System (ARIS)
removes the requirement for air by using
a return flow of urea to cool the injector
head. This enables a simple (both in
concept and installation) and effective
solution which lends itself exceptionally
well to both OE and retrofit applications

• Available under license

• Licensed to major tier one suppliers and

retrofit manufacturers worldwide.

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Key ARIS features

„ Enabling SCR technology for NOx reduction

„ Single fluid injector (integral cooling)

„ Eliminates need for compressed air

„ Opens up light duty and passenger car market

„ Protected by world wide patents

„ Low heat transfer
„ Fine Atomization Control
„ Precise injection control via solenoid actuation

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by Clean Inc
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Advanced reagent injection system (ARIS)

© Clean ©Diesel Technologies,

by Clean Inc
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Key advantages of ARIS technology

ƒ Urea reagent 'bulky' 9 Potential for reduced urea usage

ƒ Urea freezing 9 No adverse influence
ƒ Urea crystallization 9 No adverse influence
ƒ Nozzle fouling 9 Minimized due to return flow cooling
ƒ Component heavy 9 Simplified design
ƒ Compressor cost 9 Not required
ƒ Tampering & compliance 9 Potential for sensor positioning at
point of injection

© Clean Diesel Technologies,

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 Injector control pulse width modulation (PWM)

12/24 Volts

0 Volts

50% off 50% on 90% off 10%

on
Period = 0.1 sec. Period = 0.1 sec.
Pulse width injector on time illustrated
10 Hz typical injection at 50% and 10%. The industry standard
frequency is to specify between 20% and 80%
on-time to maintain accuracy &
reliability

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Urea SCR ARIS laboratory performance

„ Caterpillar 3126
„ HDD transient and steady
state modes
„ Steady state NOx:
ƒ 5.1 g/bhp-hr in
ƒ 0.4 g/bhp-hr out
ƒ 92% NOx conversion

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 CDT ARIS Gen 1 SCR Technology
Ability to Follow Load and Speed Changes
(Caterpillar 3126 Engine)

450.0 4750
400.0 4500

350.0 4250

300.0 4000

250.0 3750
3500
200.0
NOx (dilute ppm), Cat In Temp (C)

3250
150.0

Speed (rpm), Load (ft/lbs)

3000
100.0
2750
50.0 Cat Out NOx
2500 Cat In NOx
0.0
2250 SCR In Temp (C)
-50.0600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200
2000 Speed (rpm)
-100.0 Load (ft-lbs)
1750
-150.0
1500
-200.0
1250
-250.0 1000
-300.0 750
-350.0 500
-400.0 250
-450.0 0
Time (sec)

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Diesel SCR: Example applications

On-Road
Heavy Duty

Off Road
Heavy Duty

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ARIS: Light duty diesel SCR retrofit case study

Vehicle Test Results

• LDV (GMC W3500) • Mainly Highway • > 80% NOx Reduction
• Isuzu turbo intercooled • Some stop and go
diesel engine rated at 175 • Inlet & outlet NOx measured
hp at 2700 RPM.

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ARIS SCR for alternative fuel vehicles: LPG
Los Angeles Dept. Public Works
Propane Powered Transit bus

SCR Installation Urea Reservoir

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ARIS-based retrofit SCR system: LPG Buses

SCR catalyst ARIS injector

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Urea SCR field performance: Natural gas engine

„ Caterpillar G3406
„ 389 bhp natural gas engine
„ 3700 ppm NOx
„ Guaranteed 90% NOx
reduction
„ Achieved >95% NOx
reduction

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EGR-SCR concept

ƒ Patent combines SCR control with EGR for NOx reduction

ƒ Based on Clean Diesel research / test program at independent
lab
ƒ Systems approach enables optimization of diesel vehicle fuel
economy and emissions performance:
9 control fuel combustion for highest efficiency
9 Apply EGR at low temperature cycles, then reduce EGR rate
9 remove residual NOx via SCR at temperature
9 reduce urea consumption associated with SCR

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EGR-SCR optimization

ƒ With both EGR and SCR in place, engines can be fine-tuned to

deliver improved fuel efficiency and greater emissions reduction.
ƒ At low temperature operation, EGR rate is maximized to
effectively reduce NOx.
9 Higher EGR rates generally result in losses of fuel efficiency
ƒ Achieving threshold temperatures are required for urea injection to
permit liberation of ammonia and to activate the SCR catalyst.
ƒ The SCR operates at a higher temperature when the catalyst is
fully active and EGR is operated at low recirculation rate to
optimize fuel efficiency.

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EGR-SCR optimization

SCR Urea Injection Rate

EGR Rate

Exhaust Temperature

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SCR + EGR summary

9 Fundamental Innovations for Fuel

Emission Control Synergy Economy and NOx Emission Control
9 Clean Diesel provides key patents on
EGR and SCR combined
EGR
9 EGR + SCR is the approach of
NOx choice for NOx control meeting US
EPA 2010 and Euro 6 limits, with
optimized fuel efficiency
SCR
9 Synergy with SCR for NOx removal
9 Achieve proposed CO2 targets
ion
Combust
9 Licenses available from Clean Diesel
FUEL EFFICIENT directly or pass-through from
authorized licensees

© Clean Diesel Technologies,

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